Method for making a vehicle panel

Abstract

A method of forming a panel is disclosed. The method includes forming a flexible skin ( 22 ); coupling a compressible material ( 24 ) to the skin ( 22 ); positioning the skin ( 22 ) and compressible material ( 24 ) in a mold; and forming a rigid substrate ( 20 ) around the skin ( 22 ) and compressible material ( 24 ) providing a first soft region ( 12 ) wherein the compressible material ( 24 ) is disposed between the skin ( 22 ) and the substrate ( 20 ) so that a first soft region ( 12 ) is defined by the compressible material ( 24 ).

1. A component for a vehicle interior comprising:
 a flexible skin having a flange that extends substantially entirely about the periphery of the skin; 
 a compressible material coupled to the skin; 
 a rigid substrate having grooves that define an area; 
 wherein the flange of the skin is coupled to and embedded in the grooves of the substrate which provides a visual boundary between the skin and the substrate defined by the groove and extends substantially entirely about the periphery of the area over which the skin is provided; 
 wherein the area over which the skin is provided comprises a first soft region and a second soft region, the first soft region and the second soft region each defining an exposed surface of the component that is configured to be interfaced by a vehicle occupant; 
 wherein the compressible material is located between the skin and the substrate to provide the first soft region; 
 wherein a portion of the skin is in direct contact with the substrate to provide the second soft region; and 
 wherein the skin extends continuously between the first soft region and the second soft region. 
 
     
     
       2. The component of  claim 1  wherein the flange comprises a folded back configuration that forms a protrusion. 
     
     
       3. The component of  claim 2  wherein the substrate comprises a molded polymer material. 
     
     
       4. The component of  claim 3  wherein the skin is a vacuum formed and trimmed sheet of a thermoplastic olefin material. 
     
     
       5. The component of  claim 4  wherein the compressible material is a foam material. 
     
     
       6. The component of  claim 5  wherein the foam material is a closed cell foam. 
     
     
       7. The component of  claim 5  wherein the foam is bonded to the skin. 
     
     
       8. The component of  claim 1  wherein the component is a vehicle door trim panel. 
     
     
       9. The component of  claim 1  wherein the boundary is filled in to provide the appearance of a seamless transition between the skin and the substrate.